EP4279705A1 - Double layer wear and corrosion protected shank adapter - Google Patents
Double layer wear and corrosion protected shank adapter Download PDFInfo
- Publication number
- EP4279705A1 EP4279705A1 EP22174656.3A EP22174656A EP4279705A1 EP 4279705 A1 EP4279705 A1 EP 4279705A1 EP 22174656 A EP22174656 A EP 22174656A EP 4279705 A1 EP4279705 A1 EP 4279705A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- corrosion protection
- protection layer
- shank adapter
- layer
- shank
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 230000007797 corrosion Effects 0.000 title claims abstract description 128
- 238000005260 corrosion Methods 0.000 title claims abstract description 128
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 39
- 239000011651 chromium Substances 0.000 claims abstract description 32
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 31
- 238000005553 drilling Methods 0.000 claims abstract description 12
- 238000004372 laser cladding Methods 0.000 claims description 37
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 29
- 239000000758 substrate Substances 0.000 claims description 19
- 238000007747 plating Methods 0.000 claims description 16
- 238000000034 method Methods 0.000 claims description 13
- 238000000151 deposition Methods 0.000 claims description 12
- 229920002313 fluoropolymer Polymers 0.000 claims description 10
- 229910001096 P alloy Inorganic materials 0.000 claims description 8
- OFNHPGDEEMZPFG-UHFFFAOYSA-N phosphanylidynenickel Chemical compound [P].[Ni] OFNHPGDEEMZPFG-UHFFFAOYSA-N 0.000 claims description 8
- 230000008021 deposition Effects 0.000 claims description 6
- 229910019142 PO4 Inorganic materials 0.000 claims description 4
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 4
- 239000010452 phosphate Substances 0.000 claims description 4
- 239000010410 layer Substances 0.000 description 122
- 229910052759 nickel Inorganic materials 0.000 description 14
- 238000000576 coating method Methods 0.000 description 9
- 239000000463 material Substances 0.000 description 9
- 239000000203 mixture Substances 0.000 description 8
- 238000011010 flushing procedure Methods 0.000 description 7
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 6
- 239000011248 coating agent Substances 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 238000005253 cladding Methods 0.000 description 5
- 230000007547 defect Effects 0.000 description 5
- 239000011156 metal matrix composite Substances 0.000 description 5
- 238000012545 processing Methods 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 239000011435 rock Substances 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 239000012895 dilution Substances 0.000 description 3
- 238000010790 dilution Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910001092 metal group alloy Inorganic materials 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
- 208000013201 Stress fracture Diseases 0.000 description 2
- 229910001315 Tool steel Inorganic materials 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000009713 electroplating Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 229910018487 Ni—Cr Inorganic materials 0.000 description 1
- SCYYUUINVKYGRP-UHFFFAOYSA-K P(=O)([O-])([O-])[O-].[Zn+2].[Mn+2] Chemical compound P(=O)([O-])([O-])[O-].[Zn+2].[Mn+2] SCYYUUINVKYGRP-UHFFFAOYSA-K 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- GVEHJMMRQRRJPM-UHFFFAOYSA-N chromium(2+);methanidylidynechromium Chemical compound [Cr+2].[Cr]#[C-].[Cr]#[C-] GVEHJMMRQRRJPM-UHFFFAOYSA-N 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000007542 hardness measurement Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- CPSYWNLKRDURMG-UHFFFAOYSA-L hydron;manganese(2+);phosphate Chemical compound [Mn+2].OP([O-])([O-])=O CPSYWNLKRDURMG-UHFFFAOYSA-L 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 239000002905 metal composite material Substances 0.000 description 1
- UNASZPQZIFZUSI-UHFFFAOYSA-N methylidyneniobium Chemical compound [Nb]#C UNASZPQZIFZUSI-UHFFFAOYSA-N 0.000 description 1
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 238000009527 percussion Methods 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 229910003468 tantalcarbide Inorganic materials 0.000 description 1
- 229910003470 tongbaite Inorganic materials 0.000 description 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
- 239000002347 wear-protection layer Substances 0.000 description 1
- LRXTYHSAJDENHV-UHFFFAOYSA-H zinc phosphate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LRXTYHSAJDENHV-UHFFFAOYSA-H 0.000 description 1
- 229910000165 zinc phosphate Inorganic materials 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/02—Couplings; joints
- E21B17/03—Couplings; joints between drilling rod or pipe and drill motor or surface drive, e.g. between drilling rod and hammer
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
- C23C18/1601—Process or apparatus
- C23C18/1633—Process of electroless plating
- C23C18/1646—Characteristics of the product obtained
- C23C18/165—Multilayered product
- C23C18/1653—Two or more layers with at least one layer obtained by electroless plating and one layer obtained by electroplating
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/07—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing phosphates
- C23C22/08—Orthophosphates
- C23C22/12—Orthophosphates containing zinc cations
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/07—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing phosphates
- C23C22/08—Orthophosphates
- C23C22/18—Orthophosphates containing manganese cations
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
- C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
- C23C22/07—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing phosphates
- C23C22/08—Orthophosphates
- C23C22/18—Orthophosphates containing manganese cations
- C23C22/182—Orthophosphates containing manganese cations containing also zinc cations
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/10—Electroplating with more than one layer of the same or of different metals
- C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
- C25D5/14—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium two or more layers being of nickel or chromium, e.g. duplex or triplex layers
Definitions
- the present invention relates to a shank adapter for top hammer rock drilling having a corrosion and / or wear protection layer.
- Shank adapters are used in rock drills as the main component which transfers the impact energy from the piston to the drill string while being rotated. Further, shank adapters are used to transfer flushing media from the rock drill into the drill string. Since shank adapters need to have high impact resistance, they are typically made from high strength carburized steel. However, the drawback of this material is that it is corroded by the flushing media, which may for example contain chloride, sulphide or other ions which accelerate the corrosion. If the shank adapter is corroded, its functionality decreases. The steel may for example have issues with stress corrosion cracking as the mechanical strength of the material is decreased.
- a known method of corrosion protection on shank adapters is to provide a single layer of hard chrome plating on its surface.
- the hard chrome layers contain pores and microcracks which can act as channels for the water to penetrate through and reach the surface of the shank adapter therefore removing the corrosion protection. Therefore, the problem to be solved is how to improve the corrosion and / or wear resistance of surfaces of the shank adapter.
- a shank adapter to form part of a drilling assembly, the shank adapter comprising: a longitudinal axis; an external surface; an internal surface; a threaded part provided at a forward end and a plurality of splines provided at a rearward end; and a machine part extending axially between the threaded part and the splines; characterised in that at least a part of the external surface is coated with a first corrosion protection layer comprising chromium and a second corrosion protection layer.
- the combination of the first and second corrosion protection layers provides increased corrosion protection.
- the thickness of first corrosion protection layer is between 5-200 ⁇ m.
- this thickness provides the optimal balance between providing sufficient corrosion protection without adding excessive costs.
- the second corrosion protection layer comprises chromium.
- the double chrome layer reduces the amount of uncontrolled micro fractures acting as channels to the steel substrate which are formed during the chromium coating process. This is done by first applying a first chrome layer on the shank adapter. This first chrome layer is thereafter polished before the second chrome layer is applied on top of the first. This results that an "interface" being is formed between the first and second layer which prevents the cracks to run through the entire layers, resulting in that less water can penetrate through the layer.
- the thickness of second corrosion protection layer is is between 5 - 200 ⁇ m.
- this thickness provides the optimal balance between providing sufficient corrosion protection without adding excessive costs or the layer becoming so thick that it becomes unstable from the additional internal stresses within the layer that is built up.
- the shank adapter further comprises a third corrosion protection layer comprising chromium.
- a third corrosion protection layer comprising chromium.
- the second corrosion protection layer is a laser cladding layer.
- the laser cladded layer would add a cost-efficient wear and corrosion protective layer.
- Laser cladding is a fast which is advantageous for production and produces a more reliable corrosion protection layer which will increase the lifetime of the shank adapter and other drilling components that attach to the shank adapter.
- the heat effected zone extends ⁇ 0.3 mm into a substrate.
- the reduction in the depth of the heat effected zone provides an increase in the wear resistance of the laser cladding layer.
- the second corrosion protection layer is a nickel phosphorus alloy plating and a fluoroplastic layer.
- the combination provides improved wear and corrosion resistance.
- the second corrosion protection layer comprises nickel.
- the combination of the nickel and chromium corrosion protection layers provides increased resistance against corrosion and wear.
- the first corrosion protection layer and the second corrosion protection layer are located on the machine part.
- this provides corrosion protection to the region of the shank adapter that is most exposed to corrosion and most important to be protected from corrosion.
- the first corrosion protection layer is located between the external surface of the shank adapter and the second corrosion protection layer.
- the shank adapter further comprises a layer of phosphate between the external surface and the first corrosion protection layer.
- this adds additional corrosion protection.
- this produces a shank adapter having increased corrosion protection.
- the addition of the second corrosion protection layer is selected from chromium plating, laser cladding or deposition of a nickel phosphorus alloy plating with or without a fluoroplastic layer.
- the second corrosion protection layer is deposited using extreme high-speed laser application (EHLA).
- EHLA extreme high-speed laser application
- EHLA provides thinner layers, with a reduced heat effected zone as the dilution between the cladding and the substrate is smaller, with higher power efficiency and faster processing times.
- Figure 1 shows a shank adapter 2 to form part of a drilling assembly, the shank adapter 2 comprising, a longitudinal axis 4; an external surface 6; an internal surface 8; a threaded part 10 provided at a forward end 12 and a plurality of splines 32 that project radially outward provided at a rearward end 14; and a machine part 16 (otherwise known as a main body) extending axially between the threaded part 10 and the splines 32.
- the splines 32 are configured to be engaged by corresponding splines of a drive bushing in a rotational motor (not shown) to induce rotation of the shank adaptor 2 about axis 4 during drilling operations.
- the threaded part 10 could be either a male or female thread.
- the shank adapter further comprises a flushing hole 26 (or bore) located on the machine part 16 that extends radially through the machine part 16 from the external surface 6 to an internal cavity or region extending axially within the shank adaptor 2.
- the shank adaptor 2 is configured for coupling to an elongate drill string and to allow transmission of a stress wave to a drill bit (not shown) located at the deepest region of the drill hole to impart the percussion drilling action.
- the forward end 12 may be coupled to a rearward end of a rearwardmost elongate drill rod forming a part of the drill string or to a coupling (not shown).
- the rearward end 14, otherwise known as the striking face, is configured to be contacted by a hydraulically driven piston (not shown) that creates the stress wave within the shank adaptor 2 and the drill string.
- the forward end 12 also comprises an annular shoulder 28 from which the threaded part 10 axially projects.
- a slim 30 is positioned axially between the machine part 16 and the threaded part 10.
- Figure 2 shows that at least a part of the external surface 6 is coated with a first corrosion protection layer 18 comprising chromium and a second corrosion protection layer 20.
- first corrosion protection layer 18 is between 5-200 ⁇ m, more preferably between 7-100 ⁇ m, even more preferably between 10-50 ⁇ m.
- the second corrosion protection layer 20 comprises chromium.
- the thickness of second corrosion protection layer 20 is between 5-200 ⁇ m, more preferably between 7-100 ⁇ m, even more preferably between 10-50 ⁇ m.
- FIG. 3 shows an alternative embodiment wherein the shank adapter 2 further comprises a third corrosion protection layer 22 comprising of chromium positioned on top of the second corrosion protection layer 20.
- third corrosion protection layer 22 when the thickness of third corrosion protection layer 22 is between 5-200 ⁇ m, more preferably between 7-100 ⁇ m, even more preferably between 10-50 ⁇ m.
- the second corrosion protection layer 20 is a laser cladding layer.
- the thickness second corrosion protection layer 20 is between 10 - 2000 ⁇ m, preferably between 10 - 800 ⁇ m, more preferably 20 - 200 ⁇ m.
- the laser cladding layer(s) is /are applied such that the outer diameter of the section of the shank adapter 2 where the laser cladding layer(s) has been applied is substantially uniform.
- the composition of the laser cladding layer comprises a metal matrix composite (MMC).
- MMC comprises a hard metal for example this could be tungsten carbide, chromium carbide, titanium carbide, tantalum carbide, niobium carbide or any other carbide or nitride or a mixture thereof and a metal alloy as a binder which could for example comprise cobalt, nickel, iron, chromium or a mixture thereof.
- the presence of the metal matrix composite increases the wear resistance of the laser cladding.
- the composition of the laser cladding corrosion protection layer comprises a metal alloy.
- the composition of the laser cladding material could be stainless steel or tool steel.
- the composition of the laser cladding material could for example be pure nickel, a nickel-based alloy e.g. a Ni-Cr alloy; an Fe based alloy; a Cr-based alloy; a mixture thereof or any other suitable material.
- the material selected can be chosen to suit the specific application and drilling environment, for example stainless steel will provide better corrosion protection, whereas tool steel or hard metal composite will provide better wear resistance.
- the metal alloy can be selected having superior corrosion and /or wear resistance to suit the application.
- the laser cladding has a hardness of between 180 to 1500 HV10, more preferably 400-1400 HV10 , even more preferably 500-1300 HV10.
- the coating is dense enough to prevent water from reaching the external surface 6 of the machine part 16. Hardness measurements are an average value for the cladded layer.
- the hardness of the metal matrix is 500-900 HV10, preferably 600-900 HV10, more preferably 600-900 HV10 and the hardness of the hard metal phase is 1500-3500 HV0.1, preferably 2000-3500 HV0.1 and most preferably 2500-3500 HV0.1.
- this provides increased wear resistance.
- the heat effected zone extends ⁇ 0.3 mm into the substrate, preferably ⁇ 0.2 mm, more preferably less than 0.1 mm.
- the heat effected zone is defined as being the area of heat altered substrate material between the applied coating and the unaffected substrate.
- the substrate is the surface that the laser cladding layer is applied to, therefore is most likely to be the chromium of the first corrosion protection layer 18 but could also be the steel of the external surface 6 of the shank adapter 2.
- the second corrosion protection layer 20 comprises nickel.
- a first corrosion protection layer comprising nickel
- the nickel is alloyed with sulphur, phosphorus, boron or any other suitable element.
- the second corrosion protection layer 20 is a nickel phosphorus alloy plating and a fluoroplastic layer.
- a Nedox coating could be used.
- the thickness of the nickel phosphorus alloy plating and a fluoroplastic layer is between 10 - 50 ⁇ m.
- the nickel phosphorus alloy plating and a fluoroplastic layer is positioned on top of the chromium layer.
- At least part of the internal surface 8 is additionally coated with a first corrosion protection layer 18 comprising nickel.
- the first corrosion protection layer 18 is located on the machine part 16. In other words, the first corrosion protection layer 18 is not positioned on the splines 32 or the threaded part 10. Alternatively, the entire external surface 6 of the shank adapter 2 is coated with a first corrosion protection layer 18.
- the laser cladding layer(s) is / are positioned around the flush hole 26 that extends radially and longitudinally through the machine part 16.
- this provides corrosion / wear protection in the region that is most subjected to corrosive attack and wear.
- the second corrosion protection layer 20 is present in all areas on the external surface 6 of the shank adapter 2 where the first corrosion protection 18 is located.
- this is most likely to be the machine part 16.
- this will provide optimal corrosion protection.
- one or more areas of the external surface 6 of the shank adapter 2 are coated with both the first corrosion protection layer 18 and the second corrosion protection layer 20 and one or more areas of the external surface 6 of the shank adapter are coated with only the first corrosion protection layer 18 or only the second corrosion protection layer 20.
- the first corrosion protection layer 18 is located between the external surface 6 of the shank adapter 2 and the second corrosion protection layer 20 as shown in figure 3 .
- the second corrosion protection layer 20 is located between the external surface 6 of the shank adapter 2 and the first corrosion protection layer 18.
- Another aspect of the present application relates to a method of providing corrosion protection on a shank adapter 2 comprising the step of:
- the chromium of the first corrosion protection layer 18 is applied using electroplating.
- the second corrosion protection layer 20 is selected from chromium plating, laser cladding or deposition of a nickel phosphorus alloy plating and a fluoroplastic layer.
- the second corrosion protection layer 20 is nickel it can be applied using an electroless nickel bath or using electroplating .
- electroless nickel plating the object instead reacts to the plating bath chemistry, creating a uniform and smooth, layer with very little surface porosity. The even deposition makes it an ideal choice for complex, non-line of sight, geometries and often eliminates grinding after plating.
- the nickel plating is applied to improve the corrosion and wear resistance of an object.
- the nickel layer could be added using a laser cladding method, for example EHLA laser cladding.
- the first corrosion protection layer 18 is added before the second corrosion protection layer 20.
- the second corrosion protection layer 20 is added on top of the first corrosion protection layer 18, but it could be the other way around.
- the second corrosion protection layer 20 is a laser cladding layer.
- Laser cladding is a melting process where a laser beam is used to fuse a powder alloy with another metallurgical composition onto a substrate. A metallic substrate is exposed to a laser beam while a powder is injected over the melted bath to form, after being solidified, a layer referred to as the cladding on the surface of the substrate.
- the key benefit is that only a very thin layer of the substrate has to be melted in order to achieve a metallurgical bond between the added material and the substrate.
- the laser cladding could be applied using a fiber, C02, YAG or diode laser or any other suitable laser.
- the laser cladding is done using extreme high-speed laser material deposition (EHLA).
- EHLA is a laser cladding method which is up to 10 times faster than traditional laser cladding methods in terms of surface coverage rate.
- the high-speed deposition from EHLA does not only result in a faster processing time, it also makes it possible to apply cladding to a substrate with even lower heat input and smaller distortion, meaning that the heat effected zone will be even less in the substrate.
- the small dilution formed by EHLA makes it possible to apply even thinner coatings, the thickness of the laser cladding layers is for example typically only 25-400 ⁇ m thick.
- this inputs less energy into the substrate that the laser cladding is applied to, resulting in reduced substate melting, therefore the wear and corrosion resistance of the substrate is maintained.
- EHLA provides thinner layers, with a reduced heat effected zone as the dilution between the cladding and the substrate is smaller, with higher power efficiency and faster processing times.
- the surface that the laser cladding layer is applied to is ground and / or polished prior to application of the laser cladding layer(s).
- this increases the adhesion of the laser cladding corrosion protection layer to the external surface of the shank adapter.
- the surface that the laser cladding layer is applied to may be left unground, which has the advantage of quick processing time.
- surface that the laser cladding layer is applied to could be carburized and / or pre-heated prior to laser cladding.
- the outermost laser cladding layer is ground and / or polished.
- this reduces wear on the seals and therefore the lifetime of the product is increased and may reduce the area where possible cracks can be initiated from.
- the surface could be left unprocessed, which has the advantage of decreasing processing time.
- the laser cladding step is done after the application of the first corrosion protection.
- the steps could be done in any order as desired.
- the method further comprising the step of applying fluoroplastic layer.
- the fluoroplastic layer could be applied using a spraying technique, following by a heat treatment for curing.
- the shank adapter further comprising a layer of phosphate between the external surface 6 and the first corrosion protection layer 18.
- the phosphate layer could be selected from, but not limited to zinc phosphate, zinc manganese phosphate, or manganese phosphate.
- the shank adapter as described hereinbefore or hereinafter could be part of a drill string and / or a drill rig arrangement.
- Corrosion testing was performed on samples cut from a chromed machine part of the shank adapter, nearest the thread. Salt and acetic acid solution was sprayed on the samples and examined after different time intervals. Prior to each check, the samples were rinsed in water and excess corrosion products were washed off. The sample was then examined under a bright spot light to create a bright reflective band on the curved surface and when a defect passed the reflective band the buckling could be seen in the reflective band since it would deflect the light and the defect was marked with black pen. The chromed surface was examined over the entire circumference and the number of defects were counted per sample.
- Table 1 Number of defects observed on chrome plated surface Sample A (comparative) B (invention) C (invention) Coating Single chromium layer - 50 ⁇ m thick Double chromium layer - both layers 25 ⁇ m thick Double chromium layer - both layers 40 ⁇ m thick 0 days 0 0 0 1 day 0 0 0 10 days 4 0 0 19 days 50 2 0
- inventive samples have significantly less defects post the corrosion testing, therefore demonstrating their superior corrosion resistance.
- Table 2 Visual inspection of shank adapters post drilling Shank adapter sample Corrosion protection coating Pitting on chrome surface Crevice corrosion or wear on chromed surface A (comparison) Single chromium layer - 50 ⁇ m thick 5 5 B (invention) Double chromium layer - both layers 25 ⁇ m thick 3 4 C (invention) Double chromium layer - both layers 40 ⁇ m thick 1 3
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Abstract
A shank adapter to form part of a drilling assembly, the shank adapter comprising a longitudinal axis; an external surface; an internal surface; a threaded part provided at a forward end and a plurality of splines provided at a rearward end; and a machine part extending axially between the threaded part and the splines; characterised in that: at least a part of the external surface is coated with a first corrosion protection layer comprising chromium and a second corrosion protection layer.
Description
- The present invention relates to a shank adapter for top hammer rock drilling having a corrosion and / or wear protection layer.
- Shank adapters are used in rock drills as the main component which transfers the impact energy from the piston to the drill string while being rotated. Further, shank adapters are used to transfer flushing media from the rock drill into the drill string. Since shank adapters need to have high impact resistance, they are typically made from high strength carburized steel. However, the drawback of this material is that it is corroded by the flushing media, which may for example contain chloride, sulphide or other ions which accelerate the corrosion. If the shank adapter is corroded, its functionality decreases. The steel may for example have issues with stress corrosion cracking as the mechanical strength of the material is decreased.
- Further, it is important to maintain the integrity of the seals inside the flushing housing for preventing leakage of the flushing water and maintaining good flushing pressure. For the seals to not wear out prematurely, it is important that the surface of the shank adapter in contact with the seals remains in a good, non-corroded condition. A corroded surface is highly abrasive and leads to premature failure of the seals in the flushing housing of the rock drill.
- Therefore, it is advantageous to provide a corrosion protection coating on the surface of the shank adapter.
- A known method of corrosion protection on shank adapters is to provide a single layer of hard chrome plating on its surface. However, the hard chrome layers contain pores and microcracks which can act as channels for the water to penetrate through and reach the surface of the shank adapter therefore removing the corrosion protection. Therefore, the problem to be solved is how to improve the corrosion and / or wear resistance of surfaces of the shank adapter.
- It is an objective of the present invention to provide an alternative means to increase the corrosion and / or wear resistance of shank adapters. This objective is achieved by providing a shank adapter to form part of a drilling assembly, the shank adapter comprising: a longitudinal axis; an external surface; an internal surface; a threaded part provided at a forward end and a plurality of splines provided at a rearward end; and a machine part extending axially between the threaded part and the splines; characterised in that at least a part of the external surface is coated with a first corrosion protection layer comprising chromium and a second corrosion protection layer.
- Advantageously, the combination of the first and second corrosion protection layers provides increased corrosion protection.
- In one embodiment, the thickness of first corrosion protection layer is between 5-200 µm. Advantageously, this thickness provides the optimal balance between providing sufficient corrosion protection without adding excessive costs.
- In one embodiment, the second corrosion protection layer comprises chromium. Advantageously, the double chrome layer reduces the amount of uncontrolled micro fractures acting as channels to the steel substrate which are formed during the chromium coating process. This is done by first applying a first chrome layer on the shank adapter. This first chrome layer is thereafter polished before the second chrome layer is applied on top of the first. This results that an "interface" being is formed between the first and second layer which prevents the cracks to run through the entire layers, resulting in that less water can penetrate through the layer.
- In one embodiment, the thickness of second corrosion protection layer is is between 5 - 200 µm. Advantageously, this thickness provides the optimal balance between providing sufficient corrosion protection without adding excessive costs or the layer becoming so thick that it becomes unstable from the additional internal stresses within the layer that is built up.
- In one embodiment, the shank adapter further comprises a third corrosion protection layer comprising chromium. Advantageously, this further reduces the level of uncontrolled micro fractures acting as channels to the steel substrate which are formed during the chromium coating process.
- In one embodiment, the second corrosion protection layer is a laser cladding layer. Advantageously, the laser cladded layer would add a cost-efficient wear and corrosion protective layer. Laser cladding is a fast which is advantageous for production and produces a more reliable corrosion protection layer which will increase the lifetime of the shank adapter and other drilling components that attach to the shank adapter.
- In one embodiment, the heat effected zone extends < 0.3 mm into a substrate. Advantageously, the reduction in the depth of the heat effected zone provides an increase in the wear resistance of the laser cladding layer.
- In one embodiment, the second corrosion protection layer is a nickel phosphorus alloy plating and a fluoroplastic layer. Advantageously, the combination provides improved wear and corrosion resistance.
- In one embodiment, the second corrosion protection layer comprises nickel. Advantageously, the combination of the nickel and chromium corrosion protection layers provides increased resistance against corrosion and wear.
- In one embodiment, the first corrosion protection layer and the second corrosion protection layer are located on the machine part. Advantageously, this provides corrosion protection to the region of the shank adapter that is most exposed to corrosion and most important to be protected from corrosion.
- In one embodiment, the first corrosion protection layer is located between the external surface of the shank adapter and the second corrosion protection layer.
- In one embodiment, the shank adapter further comprises a layer of phosphate between the external surface and the first corrosion protection layer. Advantageously, this adds additional corrosion protection.
- According to another aspect of the present invention is a method of providing corrosion protection on a shank adapter as described hereinbefore or hereinafter comprising the step of:
- a) depositing the first corrosion protection layer comprising chromium on at least part of the external surface of the shank adapter;
- b) depositing the second corrosion protection layer on at least part of the external surface of the shank adapter;
- Advantageously, this produces a shank adapter having increased corrosion protection.
- In one embodiment of the method, the addition of the second corrosion protection layer is selected from chromium plating, laser cladding or deposition of a nickel phosphorus alloy plating with or without a fluoroplastic layer.
- In one embodiment of the method the second corrosion protection layer is deposited using extreme high-speed laser application (EHLA). Advantageously, EHLA provides thinner layers, with a reduced heat effected zone as the dilution between the cladding and the substrate is smaller, with higher power efficiency and faster processing times.
- A specific implementation of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which:
-
Figure 1 is a schematic drawing of a shank adapter. -
Figure 2 is a schematic drawing of one embodiment of the corrosion protection layer. -
Figure 3 is a schematic drawing of a further embodiment of the corrosion protection layer. -
Figure 1 shows ashank adapter 2 to form part of a drilling assembly, theshank adapter 2 comprising, alongitudinal axis 4; anexternal surface 6; aninternal surface 8; a threadedpart 10 provided at aforward end 12 and a plurality ofsplines 32 that project radially outward provided at arearward end 14; and a machine part 16 (otherwise known as a main body) extending axially between the threadedpart 10 and thesplines 32. Thesplines 32 are configured to be engaged by corresponding splines of a drive bushing in a rotational motor (not shown) to induce rotation of theshank adaptor 2 aboutaxis 4 during drilling operations. The threadedpart 10 could be either a male or female thread. The shank adapter further comprises a flushing hole 26 (or bore) located on themachine part 16 that extends radially through themachine part 16 from theexternal surface 6 to an internal cavity or region extending axially within theshank adaptor 2. Theshank adaptor 2 is configured for coupling to an elongate drill string and to allow transmission of a stress wave to a drill bit (not shown) located at the deepest region of the drill hole to impart the percussion drilling action. In particular, theforward end 12 may be coupled to a rearward end of a rearwardmost elongate drill rod forming a part of the drill string or to a coupling (not shown). Therearward end 14, otherwise known as the striking face, is configured to be contacted by a hydraulically driven piston (not shown) that creates the stress wave within theshank adaptor 2 and the drill string. Optionally theforward end 12 also comprises anannular shoulder 28 from which the threadedpart 10 axially projects. Optionally, a slim 30 is positioned axially between themachine part 16 and the threadedpart 10. -
Figure 2 shows that at least a part of theexternal surface 6 is coated with a firstcorrosion protection layer 18 comprising chromium and a secondcorrosion protection layer 20. - In one embodiment the thickness of first
corrosion protection layer 18 is between 5-200 µm, more preferably between 7-100 µm, even more preferably between 10-50 µm. - In one embodiment, the second
corrosion protection layer 20 comprises chromium. - In one embodiment, when the second
corrosion protection layer 20 comprises chromium, the thickness of secondcorrosion protection layer 20 is between 5-200 µm, more preferably between 7-100 µm, even more preferably between 10-50 µm. -
Figure 3 shows an alternative embodiment wherein theshank adapter 2 further comprises a thirdcorrosion protection layer 22 comprising of chromium positioned on top of the secondcorrosion protection layer 20. - In one embodiment, when the thickness of third
corrosion protection layer 22 is between 5-200 µm, more preferably between 7-100 µm, even more preferably between 10-50 µm. - In another embodiment, the second
corrosion protection layer 20 is a laser cladding layer. - In one embodiment, when the second
corrosion protection layer 20 is laser cladding, preferably the thickness secondcorrosion protection layer 20 is between 10 - 2000 µm, preferably between 10 - 800 µm, more preferably 20 - 200 µm. Preferably, the laser cladding layer(s) is /are applied such that the outer diameter of the section of theshank adapter 2 where the laser cladding layer(s) has been applied is substantially uniform. - In one embodiment, the composition of the laser cladding layer comprises a metal matrix composite (MMC). The MMC comprises a hard metal for example this could be tungsten carbide, chromium carbide, titanium carbide, tantalum carbide, niobium carbide or any other carbide or nitride or a mixture thereof and a metal alloy as a binder which could for example comprise cobalt, nickel, iron, chromium or a mixture thereof. Advantageously, the presence of the metal matrix composite increases the wear resistance of the laser cladding.
- Alternatively, the composition of the laser cladding corrosion protection layer comprises a metal alloy. The composition of the laser cladding material could be stainless steel or tool steel. The composition of the laser cladding material could for example be pure nickel, a nickel-based alloy e.g. a Ni-Cr alloy; an Fe based alloy; a Cr-based alloy; a mixture thereof or any other suitable material. The material selected can be chosen to suit the specific application and drilling environment, for example stainless steel will provide better corrosion protection, whereas tool steel or hard metal composite will provide better wear resistance. Advantageously, the metal alloy can be selected having superior corrosion and /or wear resistance to suit the application.
- Preferably, the laser cladding has a hardness of between 180 to 1500 HV10, more preferably 400-1400 HV10 , even more preferably 500-1300 HV10. Preferably, the coating is dense enough to prevent water from reaching the
external surface 6 of themachine part 16. Hardness measurements are an average value for the cladded layer. - If the cladding layer is an MMC preferably the hardness of the metal matrix is 500-900 HV10, preferably 600-900 HV10, more preferably 600-900 HV10 and the hardness of the hard metal phase is 1500-3500 HV0.1, preferably 2000-3500 HV0.1 and most preferably 2500-3500 HV0.1. Advantageously, this provides increased wear resistance.
- In one embodiment the heat effected zone extends < 0.3 mm into the substrate, preferably < 0.2 mm, more preferably less than 0.1 mm. The heat effected zone is defined as being the area of heat altered substrate material between the applied coating and the unaffected substrate.
- The substrate is the surface that the laser cladding layer is applied to, therefore is most likely to be the chromium of the first
corrosion protection layer 18 but could also be the steel of theexternal surface 6 of theshank adapter 2. - In one embodiment, the second
corrosion protection layer 20 comprises nickel. - In one embodiment, additionally at least part of the internal surface is coated with a first corrosion protection layer comprising nickel.
- Optionally, the nickel is alloyed with sulphur, phosphorus, boron or any other suitable element.
- In one embodiment, the second
corrosion protection layer 20 is a nickel phosphorus alloy plating and a fluoroplastic layer. For example a Nedox coating could be used. Preferably, the thickness of the nickel phosphorus alloy plating and a fluoroplastic layer is between 10 - 50 µm. - Preferably, the nickel phosphorus alloy plating and a fluoroplastic layer is positioned on top of the chromium layer.
- Optionally, at least part of the
internal surface 8 is additionally coated with a firstcorrosion protection layer 18 comprising nickel. - In one embodiment the first
corrosion protection layer 18 is located on themachine part 16. In other words, the firstcorrosion protection layer 18 is not positioned on thesplines 32 or the threadedpart 10. Alternatively, the entireexternal surface 6 of theshank adapter 2 is coated with a firstcorrosion protection layer 18. - In one embodiment, the laser cladding layer(s) is / are positioned around the
flush hole 26 that extends radially and longitudinally through themachine part 16. Advantageously, this provides corrosion / wear protection in the region that is most subjected to corrosive attack and wear. - In one embodiment, the second
corrosion protection layer 20 is present in all areas on theexternal surface 6 of theshank adapter 2 where thefirst corrosion protection 18 is located. - For example, this is most likely to be the
machine part 16. Advantageously, this will provide optimal corrosion protection. - In another embodiment, one or more areas of the
external surface 6 of theshank adapter 2 are coated with both the firstcorrosion protection layer 18 and the secondcorrosion protection layer 20 and one or more areas of theexternal surface 6 of the shank adapter are coated with only the firstcorrosion protection layer 18 or only the secondcorrosion protection layer 20. - Preferably, the first
corrosion protection layer 18 is located between theexternal surface 6 of theshank adapter 2 and the secondcorrosion protection layer 20 as shown infigure 3 . Alternatively, the secondcorrosion protection layer 20 is located between theexternal surface 6 of theshank adapter 2 and the firstcorrosion protection layer 18. - Another aspect of the present application relates to a method of providing corrosion protection on a
shank adapter 2 comprising the step of: - a) depositing the first
corrosion protection layer 18 comprising chromium on at least part of theexternal surface 6 of theshank adapter 2; - b) depositing the second
corrosion protection layer 20 on at least part of theexternal surface 6 of theshank adapter 2; - In one embodiment, the chromium of the first
corrosion protection layer 18 is applied using electroplating. - The second
corrosion protection layer 20 is selected from chromium plating, laser cladding or deposition of a nickel phosphorus alloy plating and a fluoroplastic layer. - In one embodiment, if the second
corrosion protection layer 20 is nickel it can be applied using an electroless nickel bath or using electroplating . In electroless nickel plating, the object instead reacts to the plating bath chemistry, creating a uniform and smooth, layer with very little surface porosity. The even deposition makes it an ideal choice for complex, non-line of sight, geometries and often eliminates grinding after plating. The nickel plating is applied to improve the corrosion and wear resistance of an object. Alternatively, the nickel layer could be added using a laser cladding method, for example EHLA laser cladding. - Preferably the first
corrosion protection layer 18 is added before the secondcorrosion protection layer 20. In other words, the secondcorrosion protection layer 20 is added on top of the firstcorrosion protection layer 18, but it could be the other way around. - In one embodiment, where the second
corrosion protection layer 20 is a laser cladding layer. Laser cladding is a melting process where a laser beam is used to fuse a powder alloy with another metallurgical composition onto a substrate. A metallic substrate is exposed to a laser beam while a powder is injected over the melted bath to form, after being solidified, a layer referred to as the cladding on the surface of the substrate. The key benefit is that only a very thin layer of the substrate has to be melted in order to achieve a metallurgical bond between the added material and the substrate. The laser cladding could be applied using a fiber, C02, YAG or diode laser or any other suitable laser. - Preferably, the laser cladding is done using extreme high-speed laser material deposition (EHLA). EHLA is a laser cladding method which is up to 10 times faster than traditional laser cladding methods in terms of surface coverage rate. The high-speed deposition from EHLA does not only result in a faster processing time, it also makes it possible to apply cladding to a substrate with even lower heat input and smaller distortion, meaning that the heat effected zone will be even less in the substrate. In addition, the small dilution formed by EHLA makes it possible to apply even thinner coatings, the thickness of the laser cladding layers is for example typically only 25-400 µm thick. Advantageously, this inputs less energy into the substrate that the laser cladding is applied to, resulting in reduced substate melting, therefore the wear and corrosion resistance of the substrate is maintained. EHLA provides thinner layers, with a reduced heat effected zone as the dilution between the cladding and the substrate is smaller, with higher power efficiency and faster processing times.
- Preferably, the surface that the laser cladding layer is applied to is ground and / or polished prior to application of the laser cladding layer(s). Advantageously, this increases the adhesion of the laser cladding corrosion protection layer to the external surface of the shank adapter. Alternatively, the surface that the laser cladding layer is applied to may be left unground, which has the advantage of quick processing time. Additionally, or alternatively, surface that the laser cladding layer is applied to could be carburized and / or pre-heated prior to laser cladding.
- Preferably, the outermost laser cladding layer is ground and / or polished. Advantageously, this reduces wear on the seals and therefore the lifetime of the product is increased and may reduce the area where possible cracks can be initiated from. Alternatively, the surface could be left unprocessed, which has the advantage of decreasing processing time.
- Preferably, the laser cladding step is done after the application of the first corrosion protection. However, the steps could be done in any order as desired.
- In one embodiment the method further comprising the step of applying fluoroplastic layer. For example, the fluoroplastic layer could be applied using a spraying technique, following by a heat treatment for curing.
- In one embodiment, the shank adapter further comprising a layer of phosphate between the
external surface 6 and the firstcorrosion protection layer 18. For example, the phosphate layer could be selected from, but not limited to zinc phosphate, zinc manganese phosphate, or manganese phosphate. - The shank adapter as described hereinbefore or hereinafter could be part of a drill string and / or a drill rig arrangement.
- Corrosion testing was performed on samples cut from a chromed machine part of the shank adapter, nearest the thread. Salt and acetic acid solution was sprayed on the samples and examined after different time intervals. Prior to each check, the samples were rinsed in water and excess corrosion products were washed off. The sample was then examined under a bright spot light to create a bright reflective band on the curved surface and when a defect passed the reflective band the buckling could be seen in the reflective band since it would deflect the light and the defect was marked with black pen. The chromed surface was examined over the entire circumference and the number of defects were counted per sample. After the investigation the samples were put back in a plastic container and sprayed with the acetic acid and NaCl solution from all sides and left under a lid until the next examination a few days later. The results are shown in table 1 below:
Table 1: Number of defects observed on chrome plated surface Sample A (comparative) B (invention) C (invention) Coating Single chromium layer - 50 µm thick Double chromium layer - both layers 25 µm thick Double chromium layer - both layers 40 µm thick 0 days 0 0 0 1 day 0 0 0 10 days 4 0 0 19 days 50 2 0 - It can be seen that the inventive samples have significantly less defects post the corrosion testing, therefore demonstrating their superior corrosion resistance.
- Shank adapters with different corrosion protection layers were tested at Kristinebergsgruvan a Boliden mine in Sweden. All samples were drilling until they were worn out and discarded. After drilling the shank adapters were visually inspected and the degree of corrosion was judged on scale of 1-5 (1 = least corrosion and 5 = worst corrosion) based on their resistance to pitting and crevicing. The results are shown in table 2 below:
Table 2: Visual inspection of shank adapters post drilling Shank adapter sample Corrosion protection coating Pitting on chrome surface Crevice corrosion or wear on chromed surface A (comparison) Single chromium layer - 50 µm thick 5 5 B (invention) Double chromium layer - both layers 25 µm thick 3 4 C (invention) Double chromium layer - both layers 40 µm thick 1 3 - It can be seen that there was a reduction in both pitting and crevice corrosion for the invention samples compared to a single layer on chromium.
Claims (15)
- A shank adapter (2) to form part of a drilling assembly, the shank adapter (2) comprising:a longitudinal axis (4);an external surface (6);an internal surface (8);a threaded part (10) provided at a forward end (12) and a plurality of splines (32) provided at a rearward end (14); anda machine part (16) extending axially between the threaded part (10) and the splines (32);characterised in that:
at least a part of the external surface (6) is coated with a first corrosion protection layer (18) comprising chromium and a second corrosion protection layer (20). - The shank adapter (2) according to claim 1, wherein the thickness of first corrosion protection layer (18) is between 5-200 µm.
- The shank adapter (2) according to claim 1 or claim 2, wherein the second corrosion protection layer (20) comprises chromium.
- The shank adapter (2) according to claim 3 wherein the thickness of second corrosion protection layer (20) is is between 5 - 200 µm.
- The shank adapter (2) according to any of the previous claims, further comprising a third corrosion protection layer (22) comprising chromium.
- The shank adapter according to claim 1 or claim 2 wherein the second corrosion protection layer (20) is a laser cladding layer.
- The shank adapter according to any of the previous claims wherein the heat effected zone extends < 0.3 mm into a substrate (6, 18).
- The shank adapter according to claim 1 or 2 wherein the second corrosion protection layer (20) comprises Ni.
- The shank adapter according to claim 8 wherein the second corrosion protection layer (20) is a nickel phosphorus alloy plating and a fluoroplastic layer.
- The shank adapter (2) according to any of the previous claims wherein the first corrosion protection layer (18) and the second corrosion protection layer (20) are located on the machine part (16).
- The shank adapter (2) according to any of the previous claims wherein the first corrosion protection layer (18) is located between the external surface (6) of the shank adapter (2) and the second corrosion protection layer (20).
- The shank adapter (2) according to any of the previous claims further comprising a layer of phosphate between the external surface (6) and the first corrosion protection layer (18).
- A method of providing corrosion protection on a shank adapter (2) according to any of claims 1-12 comprising the step of:a) depositing the first corrosion protection layer (18) comprising chromium on at least part of the external surface (6) of the shank adapter (2);b) depositing the second corrosion protection layer (18) on at least part of the external surface (6) of the shank adapter (2);wherein the step a) or b) could be performed first.
- The method according to claim 13 wherein the second corrosion protection layer is selected from chromium plating, laser cladding or deposition of a nickel phosphorus alloy plating and a fluoroplastic layer.
- The method according to claim 13 or 14 wherein the second corrosion protection layer (20) is deposited using extreme high-speed laser application (EHLA).
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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EP22174656.3A EP4279705A1 (en) | 2022-05-20 | 2022-05-20 | Double layer wear and corrosion protected shank adapter |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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EP22174656.3A EP4279705A1 (en) | 2022-05-20 | 2022-05-20 | Double layer wear and corrosion protected shank adapter |
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EP4279705A1 true EP4279705A1 (en) | 2023-11-22 |
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EP22174656.3A Withdrawn EP4279705A1 (en) | 2022-05-20 | 2022-05-20 | Double layer wear and corrosion protected shank adapter |
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Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100059285A1 (en) * | 2006-05-17 | 2010-03-11 | Carlstroem Bo | Top hammer rock-drilling tool, a drill rod coupling sleeve |
EP2614212A2 (en) * | 2010-09-09 | 2013-07-17 | Atlas Copco Secoroc AB | Shank adapter with corrosion protection |
EP3916114A1 (en) * | 2019-01-25 | 2021-12-01 | Furukawa Rock Drill Co., Ltd. | Drill tool and method for producing same |
-
2022
- 2022-05-20 EP EP22174656.3A patent/EP4279705A1/en not_active Withdrawn
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100059285A1 (en) * | 2006-05-17 | 2010-03-11 | Carlstroem Bo | Top hammer rock-drilling tool, a drill rod coupling sleeve |
EP2614212A2 (en) * | 2010-09-09 | 2013-07-17 | Atlas Copco Secoroc AB | Shank adapter with corrosion protection |
EP3916114A1 (en) * | 2019-01-25 | 2021-12-01 | Furukawa Rock Drill Co., Ltd. | Drill tool and method for producing same |
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